Headgear with removable rigging unit



oct. 14, 195s J. A. NLE@ 2,855,605

HEADGEAR WITH REMOVABLE RIGGING UNIT Filed Dec. 21, 1954 5 Sheets-Sheet1 0ct. 14, 1958 .1. A.A1L Eo 2,855,605

HEADGEAR WITH REMOVABLE RIGGING UNIT Filed Deo. 21, 1954 3 Sheets-Sheet2 INVENTOR. JAC/(50N //f BM AVM@ Qct. 14, 1958 J. A. AlLEo `2,855,605

HEADGEAR WITH REMovABLE RIGGING UNIT Filed Dec. 21, 1954 3 Sheets-Sheet3 HEADGEAR WITH REMOVABLE RIGGING UNIT Jackson A. Aileo, Carbondale,Pa., assigner to Leonard l. Frieder, Great Neck, N. Y.

Application December 21, 1954, Serial No. 476,623 1n claims. (C1. 2 3)The `present invention relates to headgear, and is particularlyconcerned with a novel rigging unit by'means of which a headgear may bemounted on the head of a wearer.

The novel rigging unit is illustrated herein as applied to a headgear ofthe type including a rigid helmet shell, and it has particular utilityin connection with such a shell. The rigging unit is not, however,necessarily limited to use'in connection with such a shell, but has abroader utility in connection with headgear in general.

Furthermore, certainy novel structural features illustrated inconnection with the rigging unit are not necessarily limited in theirutility to use in connection with such a unit, but may be used withother types of headgear.

A rigging unit. constructed in accordance with the present inventionincludes a headband adapted to engage the wearers head, and most of itsparts are textile structures, of webbing or the like. a rigging unittypically requires specialized operations which, in many instances, arequite different from the manufacturing operations for producing theouter covering of the headgear. This is especially true with certaintypes of headgear, for example, safety helmets having an outer rigidshell, which shell is commonly formed on a plastic molding press. It istherefore desirable to provide a headgear in kwhich the cover or shellmay be manufactured ,as one unit andthe rigging as a separate unit. Thetwo components may then be manufactured at different locations or evenin different plants, respectively` equipped Vto carry out one particularset of operations. Assembly ofthe covers or shell with the rigging unitsmay then be carried on at either of the two locations, or, at athirdlocation..

,It -is'even desirable insorne instances to sell the cover structuresand the rigging unit'separately, to be assembled by Ythe. purchaser,

safety helmets are used, such as construction projects,

it, is common` forv the contractor to own the head gearV usedbythe'vvorkersQjA. headgear is issued to a worker when. he fcomesonther-job and he turns it in when he leaves. 'lt is thendesirable-tohavel the textile rigging unit dry cleaned, or perhapsreplaced, before the headgear is issued to some other`n worker. It isnot convenient to Yclean the complete'helmetand rigging headgearforfseveral reasons,"` For-examplejsome cleaning liuidsmayattaclgthaplastic used to form the helmet shell. ltisfalso.desirablein many'instances to provide a new riggingtoreplaceone whichiseworn out, in a shell which is'still serviceable.H x

Anotheradvantage to? the manufacture of the cover structures .andythe-rigging *unit separately liesv in the greater ease `of shipment.VWhere a safety helmet cornprisesA a rigitlshell structure and aVpermanently fastened The manufacture of such For example, in many fieldswhere y United* States Patent O rigging, then it isdiliicultto ship`more than one such lCC Where the rigging unit and the shell structureare manufactured separately, the shells nest easily together and many ofthem may be shipped nested together in a single box or carton.Similarly, the rigging units, particularly the textile portions thereof,may be attened readily to their minimum volume. In order to secure theseadvantages from the separate manufacture of the shells and riggingunits, it is essential that the rigging unit be capable of rapid andeasy assembly with the shell, without the necessity of using tools orthe turning of screws or the like.

It is an object of the present invention to provide an improved riggingunit for supporting a headgear on the wearers head.

Another object of the invention is to provide improved means forassembling a rigging unit with an outer covering such as a helmet shell.

Another object is to provide improved means for adjusting a rigging unitto fit the head of a wearer.

Another object is to provide an improved headband structure for aheadgear.

Another object is to provide an improved headstrap including a stifflyresilient annulus provided at spaced g' intervals about its peripherywith apertures for receiving strap members. The strap members extendthrough certain of the apertures in the annulus and thence radiallyinwardly and through loops formed in the periphery of a headbandstructure adapted to engage the wearers head. After passing through theloops, the vstrap members extend radially outwardly 'and through otherapertures opening in the annulus. also have portions which extenddiametrically across from one side of the annulus to the other and serveas headstraps. The centering of the headband within the annulus and thelength of the headstraps may be easily and independently adjusted byslipping the strap members through the apertures. After adjusting, theselengths may be fixed by suitable means, a preferred arrangement beingshown and described. The headband is also made adjustable, so that thesupporting rigging is completely adjustable to the wearers head and withrespect to the centering of the annulus on the wearers head.

A headband of greatly improved flexibility is provided by making theheadband from bias cut leatherette, or other plastic coatedfabricmaterial. An internal band somewhat longer than the leatherette band andformed of webbing or other high strength material may be inserted insidethe band to take theV stress thereon when the leatherette stretchesbeyond a certain point.

A novel headstrap structure is provided, of a generally spider shapedformation with the several head straps radiating from a central portion.The central portion may be one solid piece, or it may be annular, inwhich case it may be circularly -annular or elliptically annular.

The rigging unit is disclosed herein as being mounted in a moldedplastic helmet shell whose inner contour conforms to that of theperiphery ofthe annulus. A plurality of lugs project inwardly from theshell at spaced intervals around its inner surface. The annulus isadapted for mounting 0n these lugs, either by resting on their uppersurfaces, or by having apertures formed in it for receiving the lugs.The annulus has its unstressed outer diameter substantially equal to theinner The strap members may diameter of the shell, so that when therigging unit is in place in the shell, the several straps are clampedbetween the annulus and the shell, and are thereby fixed as to theiradjusted lengths.

The rigging unit is inscrtable into and removable from the shell bybending the annulusinwardly so that it clears one or more of the lugs,as may be necessary.

Other objects and advantages of the invention will become apparent froma consideration of the follofving specification, claims and drawings.

In the drawings:

Fig. 1 is a bottom plan view of a helmet provided with a riggingembodying the invention;

Fig. 2 is a vertical sectional view of the helmet rigging of Fig. l,taken on the line II-il of Fig. l;

Fig. 3 is a fragmentary sectional view taken on the line III-H1 of Fig.1;

Fig. 4 is a fragmentary sectional view taken on tie line IV-flV, of Fig.l;

Fig. 5V is a fragmentary sectional view similar to Fig. 4, illustratinga modification ofthe invention;

Fig. 6 is another fragmentary sectional view similar to Fig. 4,illustrating another modification;

Fig. 7 is a fragmentary sectional view similar to Fig. 3, illustrating amodification;

Fig. 8 is an elevational developed view of the inner side of one of theheadband elements, with a portion broken away;

Fig. 9 is a view similar to Fig. 8, showing a modification;

Fig. 10 is a fragmentary plan view of a modiedheadstrap arrangement; and

Figs. 1l and l2 are views similar to Fig. l0, showing other modications.

Referring to the drawings, there is shown a helmet shell 1, of generallyconventional contour having the lower portion 1a of its side wallsslanted inwardly in an upward direction. In the lower portion 1a of thelhelmet, the cross-sectional contour of the inner surface issubstantially a straight line. While other inner surw face contours maybe used, Within the broader aspects of the present invention, it isgreatly preferred to use a contour having a straight line cross-sectionin this portion of the helmet shell. Such a contour facilitates themolding of the helmet shell.

On the inner surface of the shell 1, in the lower region 1a, there arebonded a plurality of inwardly projecting lugs 2. It is preferred tomake the shell 1 and the lugs` 2 of electrical insulating material.There are then no apertures in the shell nor are there any metalitpieces projecting through the shell through which an electric currentcould reach the wearers head.

Inside the shell is mounted a rigging unit comprising an annulus 3 ofstiffly resilient plastic material, a headband 4 adapted to engage thewearers head, and a. plurality of straps 5, which serve both asheadstraps er:- tended over the wearer-s head between diametricallyopposite portions of the annulus 3 and also as connections between theheadband 4 and the annulus 3.

Each end of each headstrap 5 is arranged as best seen in Fig. 3. Theannulus 3 is provided, adjacent each headstrap end, with a series 0fthree vertically aligned aperturesa, 3b and 3c. These apertures extendradially through the annulus 3 from its inside to its outside. The endof strap S extends outwardly through the upper aperture 3a,Vthendownwardly along the. outside of tbe annulus 3 and inwardly throughthe lower aperture On lthe periphery of the headband 4, a plurality ofshort bands or keepers 6 are attached at their ends to the headband 4andare free of the headband at their center. After passing through theaperture 3c in the annulus 3, a loop portion Sa of the strap 5 extendsradially inwardly to the headband 4, upwardly through the loop formed byone of, the bands 6, thence radially outwardly through the centeraperture 3b, upwardly along the outside of the annulus 3, andinwardlythrough the upper aperture 3a. The inner end 5c of the strap 5 is leftfree.

It may be seen that the straps 5 are attached to the annulus 3 and tothe headband 4, without the use of any stitching in the strap 5. Whenthe rigging unit including the annulus 3, the headband 4 and the straps5 are removed from the shell 1, then the length of each of theheadstraps 5 may be adjusted by slipping the straps through theapertures 3a and 3b. After the headstrap length is established, thelengths of the loop portions 5e may be adjusted by slipping the strap 5through the apertures 3a, 3b and 3c. When the rigging unit is in placein the shell 1, the portions of the strap 5 which lie along the outsideof the annulus 3 are effectively clamped between the annulus and theshell and these adjustments are thereby fixed.

The headband 4 comprises front and rear sections 4a and 4b, whose endsare connected by means of buckles 7 (see Fig. 1). These buckles areprovided to adjust the head size. After the head size is adjusted, thelengths of the headstraps 5 may be adjusted to suit the contour of thewearers head, and then the loops 5a may be adjusted to center theheadband 4 properly within the annulus 3 and hence within the shell 1.

The annulus 3 `is made of a material which is sufliciently resilient sothat it may be compressed or bent inwardly to clear the lugs 2 when therigging unit is being inserted or removed in the shell.

The annulus tightly engages the shell and effectively clamps the straps5 in their adjusted positions.

Alternatively, the annulus 3 may be constructed so that its outsidediameter when unstressed is the same as or even slightly smaller thanthe inside diameter of region la of the shell. The portions of straps 5which extend between the annulus and the shell tend to compress itinwardly, and produce a tight tit, even where the annulus is slightlysmaller than the shell.

When the region 1a of the shell and the annulus 3 have the generalcontour of a frustum of a cone, as in the structure illustrated in Figs.l to 4, then when the rigging unit is assembled in the shell, the weightof the shell is supported through the conforming .surfaces of the region1a and of the annulus 3. The lugs 2 serve as a guiding means for theannulus 3, but most of the weight of the shell is carried directly tothe annulus 3, not through the lugs 2. Similarly, shocks due to blowsreceived by the shell are transmitted directly to the anulus 3 and notthrough the lugs 2.

The rigging unit for the shell 1 is provided with a chin strap includingtwo sections 8 and 9. The ends of the sections 8 and 9 nearest theannulus are threaded through apertures 3a, 3b and 3c in the annulus, ina manner generally similar to the threading of the head straps 5. Anyequivalent manner of threading the straps 8 and 9 may be employed, aslong as portions of the straps are clamped between the annulus 3 and theshell 1. The length of the chin strap may be adjusted in the same manneras the lengths of the headstraps 5. The free ends of the strap sections8 and 9 are provided with complementary snap members 10 and 11,respectively.

Fig. 5

This gure illustrates a modification of the invention, in which thelower region of a shell 12 has vertical walls. Lugs 13 are bonded -tothe Walls 12 and project inwardly therefrom and support an annulus 14,generally similar in function to the annulus 3 of Figs. 1 to 4. In thearrangement `of Fig. 5, almost the entire weight of the shell 12 must becarried by the lugs 13. Similarly, any blows or impacts received by theshell 12 externally must be substantially transmitted through lugs 13 tothe annulus 14. For that reason, it may be desirable to make the lugs 13larger than the lugs 2 of Fig. 4.

Fig. 6 This gure illustrates a modification ofthe invention in which theannulus 3 is supported Von a plurality of lugs 15, projecting inwardlyat the edge of the brim. Although these lugs are shown asbeing moldedintegrally with the shell, they may alternatively be bonded to theshell. This modification has the advantage that no holes or otherweakening of the annulus 3 are required. In assembling the annulus inthe shell, it is sprung inwardly and forced past the lugs 15. It may beremoved in a similar manner. The number and spacing of/the lugs 15 maybe varied as desired, for example, being the same as the number andspacing of the lugs Z in Fig. l.

This modification has the further advantage that a downwardly directedexternal blow does not stress the lugs, but only tends to drive theannulus tightly against the shell.

While it is preferred to make the headstraps integral with the loopsconnecting the annulus to the headband, as described above, and Whilethere are numerous obvious advantages in doing so, the headstraps mayobviously be made separately from the loops.

Where an improved rigging unit of the type described is used with anouter covering of the rigid shell type, there are numerous advantages tobe gained by fixing the strap adjustments as shown and described, i. e.,by clamping the straps between the annulus and the shell. However, it isnot necessary to the invention in its broader aspects to clamp thestraps in that fashion, even where a rigid shell is used. Where othertypes of outer coverings are used, particularly flexible coverings,other types of strap fastenings may be preferable.

In many cases, it is advantageous to provide, at convenientcorresponding Vlocations on the annulus 3 andthe shell 1, arrows 16, 17`(Fig. 2) so that a person assembling the rigging unit with its outercover will assemble them in their. proper relative orientation, i. e.,with the fro-nt of the rigging unit at the front of the outer cover.

The lugs 15, as originally molded in the shell, extend upwardly beyondthe top of the lug as it appears in Fig. 6 and are faired into theshell 1. This facilitates the molding of the lug and the withdrawal ofthe mold from the finished shell. The upper portion of the lug is thenground off to provide the at upper surface of the lug 15 as it appearsin Fig. 6.

Fig. 7

VThis figure is similar to Fig. 3, and illustrates another manner ofthreading the ends of the headstraps through the apertures 3a, 3b and3c. In Fig. 7, the end of the headstrap 5 extends outwardly throughaperture 3a, then inwardly through aperture 3b and through the band 6,thence outwardly through the aperture 3c, upwardly along the outside ofthe annulus 3, and inwardly through the aperture 3a. The arrangement ofFig. 7 has an advantage over that of Fig. 3, in that the tipend of theheadstrap does not project inwardly towards the wearers head, and hencecannot become caught between the headband 4 and the wearers head.

In many cases, it will be desirable to stitch the loose ends of thestrap 5 to the headband portion of the strap. Such a stitchinginterferes somewhat with the adjustability of the strap, but on theother handit may be desirable where it is possible curious or medlingpersons might attempt to take the rigging apart.

Fig. 8

This ligure illustrates a headband element 18 which may be used in placeof one of the headband sections 4a and 4b, as they appear in Fig. 1. Theheadband element 18 is formed of leatherette or other similar plasticcoated fabric, and is cut on the bias, as shown in the central portionof the figure where a part of the headband is broken away to show thethread orientation on the uncoated side of the band. The bias cut pieceof leatherette is folded along its center line and stitched along threesides to form the principal portion of the headband. The

cutting of the headband element 18 on the bias gives it greaterresilience, and allows it to conform to the wearers head tightly,smoothly and without wrinkling. The plastic coating is on the inside,providing a smooth surface against the wearers head, and also limits thestretching of the material and gives it greater strength. It alsoprevents raveling. It is preferred to use leatherette or other coatedfabric having a woven fabric base and to cut the leatherette at an angleof 45 to the warp and weft threads of that fabric base. It has beenfound that acceptable results may be secured with woven fabrics cut atangles ranging down to 15 with respect to the warp or woof threads. Withknitted fabrics, the angle of the bias cut may range from 45substantially to 0 in either sense, but a cut at an angle of 45 givesthe best results. With knitted fabrics, the plastic coating isparticularly effective to prevent raveling of the bias cut material.

Loops 19 of webbing are stitched into the ends of the headband element18. The loops 19 serve to hold buckles 20 to the ends of the bandsection 18. On the outside layer of the element 18 are stitched theshort bands 6, one of which is shown in Fig. 7. These bands t are shownmore completely in Figs. 1 and 3. These bands 6 may be formed ofsubstantially inelastic webbing, or alternatively they may be formed ofelastic material, in whichcase the adjustment of the loops 5a betweenthe headband and the annulus 3 is less effective, since the elasticmaterial then tends to take up any slack in those loops.

Fig. 9

In this ligure, there is shown a modication of the band 18. There isinserted in this band an inner webbing 21 stitched at its ends to theends of the band 18 and having a length approximately one-eighth inchlonger than the unstressed length of the band section 18.

When the band section 18 is stretched longitudinally, as, for example,when `a safety helmet of the type described is subjected to an externalblow, then the plastic coated material 18 may be stretched so far thatit will tear or be permanently deformed. The provision of the webbing 21prevents any such tearing or deformation of the leatherette material,since it limits the amount by which the leatherette band 18 may bestretched.

Fig. 10

This ligure illustrates a spider type headstrap means 22, which mayreplace the headstraps 5 of Fig. l. The headstrap means 22 comprises acentral portion 22a and a plurality of radially extending straps 22b,whose ends may be handled in the same manner as the ends of theheadstraps 5. The headstrap means 22h may conveniently be stamped orotherwise cut from a single piece of fabric.

Fig. 11

This ligure illustrates another type of spider headstrap means 23including an annular central portion 23a, and a plurality of radiallyextending arms 23b. The use of the annular central portion 23a insteadof the solid central portion 22a provides a somewhat more exiblestructure, more adaptable to different head sizes and shapes.

The presence of the annulus also makes the headstrap means 23 coolerthan that shown in Fig. 10.

Fig. I2

7. stantial vertical width and an outer diameter, when unstressed,substantially equal to that of said lower inner surface of the shell, aplurality of lugs projecting inwardly from said shell and, supportingsaid annulus with itsV peripheral surface in engagement with said innerlower surface of the shell, said annulus being compressible inwardly forinsertion into and removal from the shell past said lugs, headband meansadapted to engage the head of a wearer, and rigging means cooperatingwith said headband means and said annulus to support the headgear on thehead of a wearer, said riggingmeans` comprising a plurality of straps,sets of vertically aligned apertures extending radially through saidannulus for reeeiving said straps, said straps being adjustable byslipping through said apertures and being threaded through saidapertures such that a length thereof is presented at the outer peripheryofy the annulus whereby the same is clamped therebetween and the shellto maintain the adjusted position of said straps,

2. A headgear as dened in claim l, in which said lugs extend intomatching openings in said annulus.

3. A headgear as defined in claim 1, in which the annulus has aplurality of sets of radially extending aper tures located atdiametrically opposite points forA receiving opposite ends of saidstraps.

4. A headgear as dened in claim 1, in which said apertures comprise aplurality of sets of parallel slots and in which said headband means hasa plurality of keepers and in which said straps extend tortuouslythrough two of said apertures, thence around one of saidkepers, andthence again tortuously'thr'ough two other of said apertures, thethreading of said straps through said apertures being such as to presenta length of strap between remote apertures at the outer face of saidannulus.

5. A headgear as defined in claim 1, including chin strap meansconnected at its ends to said annulus solely by threading said endstortuously through a plurality of said apertures such that part of saidends are at the outer surface of said annulus and clamped between theperiphery of the annulus and said shell.

lll

8 6. A rigging unit for a. headgear comprising an annulus of resilientmaterial compressible inwardly for assembly with anouterA covering,saidannulus having an outer face of substantialv width, a headbandadapted to engage the head of a .wearer and having a diametersubstantially smaller than said annulus, a plurality of keepers on theouter face of said headband, a plurality of sets of annular slotsl insaid annulus at diametrically opposite points thereineach set comprisingat least three parallel slots arranged in vertical alignment, aplurality of straps, at least one end of each of said straps extendingtortuousl through two said slots of `a set, thence around one of saidkeepers, and thence again tortuously through two other of said slots,`each said strap being adjustable by slipping through said slots tochange the spacing between said headband and said annulus, the threadingof said straps through said slots being such as to present a vlength olStrap between remote slots at the outer face of said annulus to providestrap surface adapted to be clamped between said annulus and the innersurface of an outer covering with which said annulus may bc assembled.

7. A rigging unit as defined in claim 6, in which cach set of slotscomprises three slots and in which opposite ends of each of said strapsare tortuously engaged with sets of slots.

References Cited in the file of this patent UNITED STATES PATENTS1,835,883 Lewis Dec 8, 1931 1,886,551 Jones Nov 8, 1932 2,136,678 DymNov. 15, 1938 2,177,145 Lewis Oct. 24, 1939 2,398,561 Ruggiero Apr. 16,1946 2,585,937 Johnson et al Feb. 19, 1952 2,665,422 Green et al Jan.12, 1954 2,741,768 Ruggiero Apr. 17, 1956 FOREIGN PATENTS 226,640Germany Sept. 5, 1909

